Apparatus for weaving tufted fabrics



April 10, 1956 G. L. MILLS APPARATUS FOR WEAVING TUFTED FABRICS Filed Jan. 24, 1955 F/GJ.

FIG. 2.

INVENTOR. GEORGE L. MILLS 4,; ATTOZA/B/S itd States Patet APPARATUS FGR v TUFTED FABRICS George L. Mills, Auburn, Maine, assignor to hates Mannfacturing Company,-a corporation or Maine Application January 24, 1955, Serial No. 483,591 Ill-Claims. .(Cl. 139-3.7)

The present invention relates to an apparatus and method useful in weaving tufted fabrics, such as those described in U. 5. Patent 2,655,950, having unrelated patterns on the two sides thereof.

The term unrelated patterns, .as used herein, is intended to mean patterns that are identical or different without being negatives of one another, as well as patterns that are not both solid.

Tufted fabrics having decorative patterns made by pile areas of terry loops or tufts on one or both sides have long been known to the art. When the tufts or loops cover the entire surface of one side of the fabric to form a solid pattern, the pattern on the other side is likewise solid, i. e., it is either coveredentirely with tufts or loops or is entirely devoid of tufts or loops. When the tufts on one side are arrange to form a given pattern in the shape of stripes, checks, figures, or the like, the tufted fabrics of the prior art have related patterns on the other side formed by tufts or loops at the places not covered by the tufts or loops on the first side, i. e., the pattern on the back of the fabric is a negative or reverse of the pattern formed on the face of the fabric. It has been considered necessary in the past to form tufted fabrics in this manner because the extra warp yarns that form the tufts on one or both sides of the fabric enter the loom from a warp beam which, of necessity, requires that each of the extra warp yarns moves forwardly as a unit. Thus, for example, if one warp yarn is reform a loop on the face of a fabric and no loop is desired on the face of the fabric next to the loop formed by the first warp yarn, then the adjacent warp yarn must form a loop at the bacl: of the fabric in order that both the extra warp yarns advance at the same speed.

It has been proposed heretofore to feed the extra warp yarns to the loom from individual cones or the like mounted in a creel so that the various extra warp yarns need not be advanced at the same rate. This proposal, while solving the basic difiiculty in weaving tufted fabrics having unrelated decorative patterns on the face and back, has created another difiiculty, namely that of properly controlling the tension of the individual extra warp yarns under rapidly changing conditions. Thus, for example, when a terry loop is to be formed, the rate of advancement of the extra warp yarn with which it is formed is momentarily several times as rapid as when the extra yarn is simply to be woven into or floated over the ground. With little or no tension on the extra warp yarn, the momentary rapid advancements would cause irregular amounts of yarn to be drawn from the supply package with resulting non-regularity of the loops formed in the surface of the cloth, depending on the size of the individual supply packages, the tension under which they are wound, and other factors such as minor twist variations which affect the friction between the reed and the surface of the yarn as the reed beats the loose yarn into the form of a loop. Furthermore, when no loop is to be formed in the cloth and the extra warp yarns are to be floated or interwoven in the ground, each of sufiic'ient tension ice on the yarn would tend to cause a loopy appearance even though no loop is desired.

In accordance with the present invention an apparatus is provided in which sudden and substantial increases in tension are avoided under these conditions. Generally, this improvement is accomplished by interconnecting, mechanically or otherwise, the shed operating mechanism for each individual extra warp yarn or group of extra warp yarns, e. g., the harness line of a jacquard head, with a mechanism for simultaneously and momentarily relieving the tension on any yarn or group of yarns actuated by that mechanism.

In the preferred embodiment of the apparatus of :the invention, a Jacquard loom, supplied in the usual manner with ground warp from a warp beam, :also has extra pileforming yarn fed to it from individual cones mounted on a creel or the like. Various means'are provided to apply a substantially constant tension to the extra warp yarns as they are drawn from the creel toward the loom. Between these tensioning devices and the loom, the extra warp yarns are individually deflected out of the shortest paths between the last tensioning device and guide means for the extra warp yarns by means of a device controlled by the jacquard head. Each of these path deflecting devices is preferably connected to the hook, neck cord or harness line used to determine the path of that particular extra warp yarn through the shed of the loom, When the extra warp yarn is actuated vin the shed to form a loop at the next pick of the loom, i. e., by raising'the harness line for that particular extra warp yarn, the path deflecting device is likewise actuated momentarily to shorten the path of the same extra warp yarn between the creel and the loom so that the tension on that extra warp yarn is reduced or at least not suddenly and substantially increased whenever a loop is to beformed. In order to reduce to a minimum the change in tension, the extent to which the path of a loop-forming extra warp yarn is momentarily shortened is made approximately equal to the increase in the length of the path of the extra warp yarn within the shed. .If .it is desired to reduce the tension on the extra warp yarn during the loop-forming operation, the extent to which its path is shortened should be greater than the increase in the length of the path in the shed. If, on the other hand, it is desired to increase the tension moderately, then the shortening of the path should be somewhat less.

In accordance with the method of the invention, the extra warp yarns enter the loom from individual sources such as spools in a creel at a substantially uniform tension when they are interwoven with or floated over the ground. Whenever certain of the extra warp yarns are actuated in the shed of the loom to form terry loops, steps are taken, such as individually and momentarily shortening the paths of the particular extra Warp yarns, to avoid sudden and substantial increases in the tension of those yarns at-the moment the loops are formed.

It will become readily apparent that the extra warp yarns are not only capableof being advanced at different rates, but that those advanced at a more rapid rate are not subjected to any undue and sudden increases in tension. By the method of the invention, the number of terry loops formed by one extra warp yarn in agiven length of fabric is entirely independent of the numberformed by the ,adjacent warp yarn, or for that matter, any of the extra Warp yarns. Furthermore, since it is not necessary for all of the extra warp yarns to be advanced at a uniform rate, it is not necessary to form a loop on the back of the fabric with a given extra warp yarn whenever it is desired not to form a loop on the face of the fabric with that particula extra warp yarn.

The apparatus and method of the invention, therefore,

have the advantage of enabling the convenient menuof the fabric may have identical pile area configurations,

such as figured patterns. The patterns on the face'and back need not be negatives of one another. It is possible to provide only the face of the fabric with decorative pile areas and to make'the back of the fabric comparatively plain in appearance, with the pile-forming yarns either woven into the ground or floated between adjacent'pile areas.

These advantages as well as the utility of the invention will. become further apparent'frorn the following detailed description made with reference to the accompanying drawing in which: 7 i

Figure l is a schematic view illustrating one preferred embodiment of the apparatus of the invention for controlling the tension under which extra terry warp yarnsenter a loom, and V Figure 2 is a view on a larger scale of an element of the apparatus shown in Figure l. 1

Referring now to Figure 1, an extra warp yarn 10 from generally at 12 advances toward a loom conventionally equipped with a Jacquard head 14, a regular warp beam 16, Whip roll 17, harnesses 19, take-up roll andicloth roll 21. The path of its advance, as shownin the drawing, is by way of guide bars 22, 24, 26, 27 and 29, through 4 line 41 through the medium of the weight 42 returns the extra warp yarn to its original position in the shed, it likewise simultaneously permitsthe eye 37, under thegravitational influence of the lingoe 39, to return to its original position and to thereby again lengthen the path of the warp yarn from the tensioning means to the loom. It

will thus be: seen that whenever a given extra warp yarn J is actuated in the shed to form a terry loop, the path of travel of that warp yarn from the tensioning means to the loom is individually and momentarily shortened to reduce the tension on the extra warp yarn entering the loom or at least to avoid any sudden and substantial increase in that 'an individualsource such as a cone 11 on a creel indicated a weighted eye 30 and a thread board 31 and around a pair of polished steel rods 32. The cone 11 is preferably provided with a conventional tension control device such as a disc 34 that ,acts as a weight on the yarn. The weighted eye 30 is provided to take up any slack that may be formed as a result of the yarn vibrating loose in the creel when the loom is not in operation and also serves ,to compensate for variations in elasticity of yarns with varying twist. The guide bars 26 are preferably felt covered to provide the proper friction to the passage of extra warp yarns and 'the thread board 31 is preferably one containing porcelain guides spaced at proper intervals for each warp yarn from the creel. The rods 32 of polished to assist in maintaining a substantially constant tension on the yarns that have been properly positioned by the thread board 31.

It' is to be understood of course that the tensioning means illustrated in Figure 1 may be varied considerably without departing from the invention, the means illustrated representing the best mode of operation presently contemplated.

Between the tensioning means, represented by members 22, 24, 26, 30, 31, 32 and 34, and the shed 36 of the loom, each extra warp yarn '10 passes through the eye 37 of a weight or lingoe 39 maintained in a preselected position betweensteelrods32'and guide 2 7 by a line 40 to determine the position of that particular extra warp yarn in the shed 36.

When the loom is in operation and the line 41, for example, isnot actuated to lift the ex tra warp yarn 710 in the shed 36 so that'that extrawarpyarn willnot form i the shed36 so that a terry loop will be formed with that yarn, the line 41 simultaneously, through the medium of line 40, raises the eye 37 and lingoe 39 so as to'shorten the path of the extra warp yarn 10 between the steel rods 42 and the guide bar 27, thereby avoiding any. sudden and substantial increases in tension on the 'extrawarp yarn due to the action of the line 41 on the extra warp 1 yarn in the shed. At the next pick of the loom, when the inFigure 1' j steel are preferably of 'a diameter of about four'inches. p The extra warp yarn is passed around both of these rods comprising a ground of'regular warp and filling threads and pile-forming extra warp yarns, said apparatus comconnected tov the hook, neck chord orharness li'ne41 used tension. 7 e Y i 1 v Figure 2 illustrates a preferred construction of the eye and lingoe 37, 39 illustrated schematically in Figure 1,

It is to be understood thatmodifications of the appara- V tus and method described will readily occur to those skilled in the art upon reading this description. All such modi fications are intended to come within the scope of the invention as defined in the following claims.

I claim:

1. Apparatus for weaving a textile fabrie' essentially comprising aground of regular warp and tillin'g threads and pile-forming extra vwarp yarns, said apparatus comprising aloom, tensioning means for maintaining substantially constant the tension of the extra warp yarns entering the loom when said yarns are not formed into loops, means for actuating preselected extra warp yarns to form loops in the fabric, and means for simultaneously avoiding sudden and substantial increases in the tension of said preselected extra warp yarns entering the loom.

ZLApparatus for'weaving a textile fabric essentially comprising a ground of regularwarp and filling threads and pileforming extra warp yarns, said apparatus comprising a loom, tensioning means for maintaining sub- ,stantially constant the tension of the extra warp yarns entering the loom when said yarns are advanced at a substantially constant rate, means for momentarily advancing preselected extra warp yarns at an accelerated rate V 'to formrloops inthe fabric, and means interconnected with said actuating means for simultaneously avoiding sudden and substantial increases in the tension of said preselected extra warp yarns upon being advanced at said accelerated rate. V v

3. Apparatus for weaving a' textile fabric essentially prising a loom, tensioning means for maintaining substantially constant the tension'of the extra warp yarns entering theloom along a given path when said yarns are advanced at a substantially constant rate, meansformomentarily advancing preselected extra warp yarns at an accelerated rate to form loops in the fabric, and means for simultaneously shortening the given path of said preselected extra warp yarns entering the loom.

4. Apparatus for weaving a textile fabric essentially. comprising a ground 'of regular warp and filling threads and pile-forming extra Warp yarns, said apparatus comprising a loom, tensioning means for maintaining sub-' stantially'constant'the tension of the extra warp yarns entering the loom, and means for momentarily reducing the tension on preselected extra warp yarns when said i preselected extra warp yarns are actuated in the shed to form loops in the fabric.

5,Apparatus for weaving a textile fabric essentially, comprising a ground of regular warp and filling threads and pile-forming extra warp yarns woven into the ground,

said apparatus comprising a Jacquard loom, tensioning means for maintaining substantially constant the 'tension of the extra warp yarns entering the loom, and means 1 V actuated by the Jacquard head for momentarily reducing the tension on preselected extra warp yarns when said preselected extra warp yarns, are actuated in the shed to form loops in the fabric.

p 6. Apparatus for weaving a textile fabric essentially comprising a ground of regular warp and filling threads and pile-forming extra warp yarns, said apparatus comprising a loom, a creel for a plurality of cones of extra warp yarns, tensioning means for maintaining substantially constant the tension of the extra warp yarns entering the loom, and means for momentarily reducing the tension on preselected extra warp yarns entering the loom when said preselected extra warp yarns are actuated in the shed to form loops in the fabric.

7. Apparatus for weaving a textile fabric essentially comprising a ground of regular warp and filling threads and pile-forming extra warp yarns, said apparatus comprising a Jacquard loom, a creel for a plurality of cones of extra warp yarns, tensioning means for maintaining substantially constant the tension of the extra warp yarns entering the loom, deflecting means between the tensioning means and the loom for deflecting the extra warp yarns to follow given paths to the loom, and means actuated by the Jacquard head for momentarily shortening the given paths of preselected extra warp yarns entering the loom when said preselected extra warp yarns are actuated in the shed to form loops in the fabric.

8. In a loom for weaving a textile fabric essentially comprising a ground of regular warp and filling threads and having means for forming terry loops with extra warp yarns entering the loom under substantially constant tension, the improvement which comprises means actuated by the loop-forming means for avoiding sudden and substantial increases in the tension on preselected extra warp yarns entering the loom when said preselected extra warp yarns are actuated by the loop-forming means. to form loops in the fabric.

9. In a Jacquard loom for weaving a textile fabric essentially comprising a ground of regular warp and filling threads and pile-forming extra warp yarns, wherein the extra warp yarns enter the loom under substantially constant tension, the improvement which comprises means actuated by the Jacquard head for momentarily reducing the tension on preselected extra warp yarns entering the loom when said preselected extra warp yarns are actuated in the shed to form loops in the fabric.

10. In a Jacquard loom for weaving a textile fabric essentially comprising a ground of regular warp and filling threads and pile-forming extra warp yarns, wherein the extra warp yarns are supplied, under substantially constant tension, to the loom from individual cones in a creel, the improvement which comprises means actuated by the Jacquard head for momentarily reducing the tension on preselected extra warp yarns entering the loom when said preselected extra warp yarns are actuated in the shed to form loops in the fabric.

References Cited in the file of this patent UNITED STATES PATENTS 2,655,950 Mills Oct. 20, 1953 

1. APPARATUS FOR WEAVING A TEXTILE FABRIC ESSENTIALLY COMPRISING A GROUND OF REGULAR WARP YARNS, SAID APPARATUS COMAND PILE-FORMING EXTRA WRAP YARNS, SAID APPARATUS COMPRISING A LOOM, TENSIONING MEANS FOR MAINTAINING SUBSTANTIALLY CONSTANT THE TENSION OF THE EXTRA WARP YARNS ENTERING THE LOOM WHEN SAID YARNS ARE NOT FORMED INTO 